U.S. patent number 5,833,271 [Application Number 08/636,041] was granted by the patent office on 1998-11-10 for file folder having a pocket.
This patent grant is currently assigned to Esselte Corporation. Invention is credited to Lee A. Boy, Allan Eugene Foster, Juan C. Gonzales, Steven Read, Mark Rocco, Harry S. Smith, Mark D. Van Leer.
United States Patent |
5,833,271 |
Foster , et al. |
November 10, 1998 |
File folder having a pocket
Abstract
A file folder has a pocket disposed on one of its surfaces. The
edges of the pocket and the file folder are in sheared alignment
with each other. A method for manufacturing a file folder having a
pocket is disclosed. Adhesive is deposited along several edges of a
first web of material which is pressed to a second web of material
to join the webs together by the adhesive. The combined materials
are cut along one of the edges of adhesive to form a sheet having a
pocket. The first and second webs have side edges which are in
sheared alignment.
Inventors: |
Foster; Allan Eugene (Yarmouth
Port, MA), Boy; Lee A. (Jamestown, NC), Read; Steven
(Fountain Valley, CA), Rocco; Mark (Chino, CA), Gonzales;
Juan C. (Chino, CA), Van Leer; Mark D. (Beaufort,
MO), Smith; Harry S. (Leslie, MO) |
Assignee: |
Esselte Corporation (Garden
City, NY)
|
Family
ID: |
24550153 |
Appl.
No.: |
08/636,041 |
Filed: |
April 22, 1996 |
Current U.S.
Class: |
281/45;
281/31 |
Current CPC
Class: |
B42F
15/04 (20130101); B42C 7/001 (20130101); B42F
15/0035 (20130101); B42F 7/02 (20130101); Y10T
156/1317 (20150115); Y10S 493/947 (20130101); Y10T
156/1727 (20150115); Y10T 156/1737 (20150115); Y10T
156/1739 (20150115); Y10T 156/1052 (20150115); Y10T
156/1724 (20150115) |
Current International
Class: |
B42F
15/00 (20060101); B42F 7/00 (20060101); B42F
7/02 (20060101); B42C 7/00 (20060101); B42D
003/00 () |
Field of
Search: |
;229/67.2,67.1,72
;281/31 ;283/36,41,45 ;40/355 ;D19/90,89 ;493/947 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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|
|
|
|
|
|
1246790 |
|
Oct 1960 |
|
FR |
|
1 354 556 |
|
Jun 1964 |
|
FR |
|
31 43 949 |
|
May 1983 |
|
DE |
|
3446783 |
|
Jun 1986 |
|
DE |
|
Other References
Jacobs Gardner Office Supply catalog, File Folders section, p. 268,
Item B, Classification folders with pocket style dividers, Dec.
1990..
|
Primary Examiner: Fridie, Jr.; Willmon
Attorney, Agent or Firm: Pennie & Edmonds LLP
Claims
What is claimed is:
1. A file folder consisting essentially of:
a first sheet of flexible material folded at a first medial line to
form a bottom edge with first and second side wall portions joined
at the bottom edge, each side wall portion terminating at a top
edge and having a pair of sheared side edges; and
a separate second sheet of flexible material attached to the first
side wall portion of the first sheet and spaced from the top edge
thereof to form a single pocket located on said first side wall
portion but not extending to said top edge, said second sheet
having a pair of side edges which are located in sheared alignment
with the side edges of the first sheet, wherein said first and
second sheets have generally parallel side edges and the second
sheet is attached to the first sheet by an adhesive.
2. The file folder of claim 1, wherein the second sheet has four
edges including a top edge, a bottom edge, and two side edges, and
an adhesive is disposed along the side edges and bottom edge so
that when the second sheet is attached to the first sheet, the
pocket is formed with an opening at the top edge of the second
sheet.
3. The file folder of claim 2, wherein the second sheet is affixed
to an internal surface of the first side wall portion of the first
sheet with the second sheet bottom edge located adjacent and
parallel to the bottom edge of the first sheet.
4. The file folder of claim 1, wherein the first and second side
wall portions include upper terminal portions adjacent the top
edges of the first sheet.
5. The file folder of claim 4, wherein at least one rod member is
disposed through the channels.
6. The file folder of claim 5, wherein a plurality of uniformly
spaced slots are disposed on an inner surface of said upper
terminal portions for receiving tabs.
7. The file folder of claim 6, wherein the bottom edge of the
folder includes at least one horizontal linear depression which
provides a crease line for forming the first medial line and at
least one of the first and second side walls includes at least one
second medial line spaced from the first medial line which,
together with the first medial line, allows for expansion of the
bottom of the folder.
8. The file folder of claim 1, wherein the first sheet is a
different color than the second sheet to provide visual
differentiation of the at least one pocket.
9. The file folder of claim 1, wherein the second sheet has four
edges and three of the four edges are substantially sealed to the
first sheet.
10. The file folder of claim 1, wherein the flexible material is
paper, the second sheet has four edges including a top edge, a
bottom edge, and two side edges, and the adhesive is disposed along
three of the four edges to form the pocket.
11. The file folder of claim 1, wherein the first sheet is made of
a different material than the second sheet.
12. A file folder consisting essentially of:
a first sheet of flexible material folded at a first medial line to
form a bottom edge with first and second side wall portions joined
at the bottom edge, each side wall portion terminating at a top
edge and having a pair of sheared side edges; and
a separate second sheet of flexible material attached to one of the
first or second side wall portions of the first sheet by an
adhesive to form a single pocket located on said side wall portion,
said second sheet having four edges including a top edge, a bottom
edge, and two side edges, and the adhesive is disposed along two
side edges and one of the top or bottom edge of the second sheet to
form the pocket,
wherein the side edges of the second sheet are located in sheared
alignment with the side edges of the first sheet.
Description
FIELD OF THE INVENTION
The present invention relates to paper office supplies, and, in
particular, to a file folder having a pocket attached thereto. The
present invention also relates to a method for manufacturing a file
folder having a pocket.
BACKGROUND OF THE INVENTION
File folders, and, in particular, hanging file folders have been
used in standard storage units such as file cabinets, desk drawers,
and the like, and are a necessary storage tool in modern offices
and businesses. Such folders in the art are best exemplified by
expired U.S. Pat. No. 2,291,724. This reference describes a file
formed by a sheet of heavy material with a central fold, which
forms the folder's bottom and open sides. Folds are provided in the
files top edges through which hanging rods are movably or immovably
fixed. The ends of these rods are exposed and notched, enabling the
file to hang on a complementary standard parallel file frame in
office storage equipment, such as filing cabinets and desk
drawers.
With the advent of the personal computer, there is often a need to
store computer disks and similar items in file folders, in addition
to paperwork. It is convenient for the user to be able to store
these types of items in separate pockets within a single file
folder. It is also desirable to be able to store documents or
similar items in a separate storage area within the same file
folder. Therefore, there is a need for a file folder which includes
a pocket for storing such items. It is also desirable to have an
efficient, cost-effective means for applying a pocket to a file
folder.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a file folder
which includes a first and second sheet of flexible material. The
first sheet is folded at a medial line to form a bottom edge with
first and second side wall portions joining at the bottom edge.
Each side wall portion has a pair of sheared side edges. The second
sheet is attached to the first sheet to form at least one pocket.
The second sheet has a pair of side edges which are located in
sheared alignment with the side edges of the first sheet.
Preferably, the first and second sheets have generally parallel
side edges. The second sheet may have four edges including a top
edge, a bottom edge, and two side edges.
The second sheet is attached to the first sheet by an adhesive. The
adhesive may be disposed along the side and bottom edges of the
second sheet so that when the second sheet is attached to the first
sheet, at least one pocket is formed with an opening at the top
edge of the second sheet.
The second sheet may be affixed to an internal surface of the first
side wall portion of the first sheet. The second sheet bottom edge
may then be located adjacent and parallel to the folded edge of the
first sheet. The first sheet may be a different color from the
second sheet to provide visual differentiation of the at least one
pocket.
The first and second side wall portions may include upper terminal
edges which are folded on themselves to form channels. At least one
rod may be disposed through the channels. A plurality of uniformly
spaced slots may be disposed on an inner surface of the upper
terminal edges for receiving label tabs. The bottom edge of the
file folder may also include at least one horizontal linear
depression which provides a crease line for forming at least one
additional medial line to allow for expansion of the bottom of the
file folder.
The method, according to the present invention, is for use in
manufacturing a file folder having a pocket. The method includes
depositing an adhesive along a first edge of a first web of
flexible material. An adhesive is also deposited on a second edge
of the first web at an angle relative to the first edge. Pressing
the first web against a second web of flexible material by feeding
them together at a work station results in joining the first web to
the second web by the adhesive. In order to form a sheet having a
pocket disposed thereon, the first and second webs are cut through
one of the edges so that at least one side of the sheet and pocket
are in sheared alignment.
The method may also include timing the deposit of adhesive on the
second edge to be operatively associated with the cutting step so
that the cutting occurs along an axis of each edge of adhesive to
be cut.
The cutting may occur on the second angled edge of adhesive and the
edge is of a width sufficient to allow cutting so that joined sides
are formed on each side of the cut. The cutting forms an open edge
and three closed edges on the first web. The second angled edge may
be substantially perpendicular to the bottom edge.
At least one edge of adhesive may be a hot melt adhesive which is
extruded in a line. The other edge of adhesive may be a hot melt
adhesive which is extruded in beads.
The method may also include folding the sheet along a medial line
to form a bottom edge with first and second side wall portions
joined at the bottom edge. The first and second side wall portions
may have upper terminal edges. The upper terminal edges may be
folded on themselves to form a channel. A rod member may be placed
in the channel. Slots may also be provided along the upper terminal
edges before folding.
The method may also include selecting different colors for the
first web and the second web to provide visual differentiation
between the webs.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred features of the present invention are disclosed in the
accompanying drawings, wherein similar reference characters denote
similar elements throughout the several views, and wherein:
FIG. 1 is a perspective view of a hanging file folder incorporating
a pocket of the present invention;
FIG. 2 is an elevated view of the interior of a file folder
incorporating the pocket of the present invention;
FIG. 3 is an end view of the file folder of FIG. 2 showing the
pocket in position on the file folder;
FIG. 4 is an elevated view of the system used to manufacture a file
folder incorporating the pocket of the present invention;
FIG. 5 is a perspective view of the pocket web and the adhesive
extruding heads of a preferred embodiment of the present
invention;
FIG. 6 is a flow chart of the timing operation of the system of the
present invention as driven by an encoder;
FIG. 7 is a flow chart of the method of manufacturing a file folder
having a pocket of the present invention; and
FIG. 8 is a flow chart of the method of manufacturing a hanging
file folder having a pocket of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a hanging file folder 10 having a front portion 12 and
a rear portion 14 divided by a medial fold 16. Terminal folds 17
are located at the upper edges of the front and rear portions
which, on the interior of the file, define slots 18 for tabs and
through which hanging rods 20 are disposed. The end portions of
each hanging rod 20 have notches 22 which are complementary to a
standard filing frame in office storage equipment, enabling the
file to hang while stored, e.g., in a file drawer. A pocket 30 is
attached to the inside of the rear portion 14 of the file folder
10. The folder 10 also includes a plurality of crease lines which
are horizontal linear depressions. The bottom of the folder 10 may
be widened to different widths by creasing different combinations
of depressions.
As shown more clearly in FIGS. 2 and 3, the pocket 30 is attached
to a standard file folder 40 by an adhesive 32 along three sides of
the pocket to define an opening along one side. As shown in FIG. 2,
the opening is defined along the top edge 34, but, in practice, may
be along any of the sides. A line of adhesive 36 is deposited along
the bottom edge 44 to preferably define a continuous bead of
adhesive. It should be noted that an intermittent bead of adhesive
may also be used instead of a continuous bead. Adhesive is also
deposited along the side edges 38 of the pocket. As is shown in
FIG. 2, it is preferable to deposit a series of beads of adhesive
42 along the side edge 38 of the pocket 40. In the preferred
embodiment, eight beads of adhesive 32 are shown. The adhesive 32
bonds the pocket 30 to the file folder 40. The individual beads of
adhesive are represented in FIG. 2 as slash marks or short lines,
which are not necessarily indicative of the actual shape or size of
the beads of adhesive in all instances. Separate beads of adhesive
may also be dot-shaped or may take on a variety of different
shapes. It should be noted that the term "edge" as used herein
refers to the position at which the adhesive is deposited. It does
not, in all cases, refer to an actual cut edge. The term "edge" may
be used interchangeably to refer to a line, a series of beads, or a
bar of adhesive.
FIG. 4 shows the system for applying the pocket 30 to the file
folder 40 of the present invention. The system includes two supply
rollers. The first supply roller 50 includes the folder material 11
which is in the form of a web. A web is a large continuous roll of
material. The web may be a roll of paper or a similar material. The
material of the preferred embodiment is an 11 point, 124 pound
basis weight paper, which is commercially available from
International Paper of Louisiana. The second supply roller 52
includes the pocket material 31, which is also in the form of a
web. The material of the preferred embodiment is a 32 pound basis
weight paper under the trade name Gatorhide, which is commercially
available from International Paper, Louisiana. The term web will be
used herein interchangeably with the word material when referring
to the pocket and/or folder material. The folder material 11 and
the pocket material 31 are preferably flexible in nature.
The folder material 11 is fed around a pair of driven S-wrap
rollers 54, 55 in order to feed the stock through the system. The
S-wrap rollers 54, 55 are operatively connected to each other so
that they rotate at the same speed in order to feed the folder
material evenly and continuously through the system. Rollers of the
type preferred are available from Cobb & Sons of Whittier,
Calif.
The pocket material 31 is pulled through the system by its contact
with the folder material 11. As the pocket material 31 is removed
from the supply roller 52, a plurality of extrusion heads are
preferably positioned to extrude an adhesive onto the pocket
material 31. Two extrusion heads are shown in FIG. 4, but more than
two may be used.
A first extrusion head 56 deposits a continuous bead which forms a
line of adhesive 36 onto one longitudinal edge of the pocket web
31. The continuous bead of adhesive 36 is preferably of a
predetermined width sufficient to attach the edge to the folder
web.
A second extrusion head 58 extrudes adhesive in a constant interval
pattern 42 onto the pocket material 31 so that the extrusion head
58 has both an "on" period, when adhesive is extruded through the
head, and an "off" period, when the extrusion head is inactive.
Preferably, the second extrusion head 58 extrudes adhesive along an
edge 42 which is perpendicular to the continuous bead of adhesive
36 and which is configured and dimensioned in a predetermined width
and length so that it spans the length of the pocket material 31 to
attach the pocket web to the folder web along that edge. Extrusion
heads of this type is commercial available from Slautterback Corp.
of Monterey, Calif.
Since the adhesive 32 is administered on one side of the pocket
material 31, a positioning roller 60 is used to position the
adhesive 32 for joining with the folder material 11. In order to
adhere the pocket material 31 to the folder material 11, both the
pocket material 31 and the folder material 11 pass between one of
the S-wrap rollers 55 and a pressure roller 62. The pressure roller
62 is situated in opposing relation to the S-wrap roller 55. The
pressure roller 62 applies force to the pocket material 31 and the
folder material 11 against the fixedly positioned S-wrap roller 55
in order to bond the adhesives disposed on the pocket material 31
to the folder material 11. The contact between the pressure roller
62 and the S-wrap roller 55 also helps to drive the webs 11, 31
through the system. It should be noted that the pressing together
of the webs does not have to occur against a driven roller. The
pressing together of the webs can occur between a nip roller (which
is not driven) and a pressure roller, where the driven roller is
located farther up stream or down stream of the pressure roller. In
this instance, the driven roller could be opposed by a nip roller
in order to feed the material through the system.
After the pocket material 31 has been pressed against the folder
material 11, the pocket material 31 is preferably fixed in position
on the folder material 11 to form a combined material 70. The
combined material 70 then passes over an intermediate roller 63 to
a cutting assembly 72 where the combined material 70 is severed
into separate pieces 40. After the combined material 70 has been
severed into independent folders 40, the folders 40 may be
processed further to include other folder features or the hanging
folder features, as shown in FIG. 1, if so desired. In addition, at
location 78, further processing of the combined material may occur
prior to cutting the combined material 70. For example, slots 18
may be punched in the combined material 70 along the terminal edges
17 to produce a hanging folder 10 or the medial fold 16 may be
created.
The cutting assembly 72 preferably includes a cutting blade 74. The
cutting blade 74 preferably moves downward, like a guillotine, to
sever the combined material 70 into individual folders 40. It
should be noted that other cutting mechanisms are contemplated for
use with the present system. For example, a guillotine-type cutter
may be used with a cutting block or anvil 76. Of importance here is
that the cutting blade 74 severs each layer of the combined
material 70 along each edge 42 of adhesive in order to split the
edge into two separate joined portions 46.
The cutting blade 74 is timed to cut the combined material 70 when
each edge 42 is positioned centrally below the cutting blade 74.
The edge 42 is of sufficient width so that when it is cut down the
middle of the edge 42, two joined edges 46 remain. In this way, a
pocket 30 is formed on each individual folder 40. The three
adhesived edges, including the bottom edge 36 and the side edges
46, create a U-shape of adhesive to form the outer edges of the
pocket 30. Advantageously, this system produces a high quality
product in an efficient manner. In addition, each pocket side edge
38 is in sheared alignment with the side edge of the folder 40 to
create a clean cut and to maximize the size of the pocket so that
it extends across the entire width of the folder. By sheared
alignment, we mean that one piece of material is interposed on
another and then both pieces of material are cut at the same time.
It is recognized that this cutting procedure usually results in the
edges of the materials being exactly aligned along the shear cut.
But, in some cases, there can be slight movement between the
materials if the cut occurs before the adhesive has completely
dried. In this second instance, the edges of the separate materials
may not be exactly aligned. In fact, it may be advantageous to cut
the pieces with a shearing motion and then, by an independent
means, move one or both of the edges so that they are not in exact
alignment. Both situations are intended to be encompassed within
the meaning of the terms "sheared alignment".
The system may also include tension control devices (not shown) in
combination with brake controls (not shown) for maintaining a
uniform tension on the webs as the supply rolls 50, 52 are
depleted. Maintaining a constant tension is important to the
overall operation of the system, particularly when dealing with
flexible materials, such as paper. Flexible materials tend to
stretch when tensioned. If the tension on the materials is not
maintained at a constant level, when the pocket web 31 is attached
to the folder web 11 and the materials relax, gapping and pulling
may result between the materials. By maintaining a constant tension
between the materials, when the materials relax, the pocket 30 will
rest properly on the folder 40. A tension control device which is
commercially available from Dover Flexo Electronics Inc. of
Rochester, N.H. may be utilized to maintain tension in conjunction
with a brake control which is commercially available from Horton of
Webster, Wis.
A preferred embodiment of the present invention is presented in
FIG. 5 showing the application of adhesive to the pocket material
31. As discussed previously, the extrusion heads are used for two
purposes. The first purpose is to apply a continuous line of
adhesive 36 along one longitudinal edge of the pocket material 31.
The second purpose is to apply lines of adhesive 42 transversely
across the pocket material 31 in a line which is angled relative
to, and preferably perpendicular to, the continuous bead 36. In the
preferred embodiment, this is accomplished by using four extrusions
heads 58, each of which emits two beads of adhesive 42 onto the
pocket material 31 through a dual orifice 64. It should be noted
that individual beads of adhesive may be used instead of lines of
adhesive to perform the same function as lines, and vice versa.
Advantageously, when individual beads are deposited on a material
and a second material is pressed onto the first material, the beads
of adhesive will typically spread out to form a continuous line. It
should also be noted that it may be desirable to deposit beads
which do not spread out to form a continuous line. This may be
desirable where a non-continuous line of adhesive is sufficient to
hold the material in place and for the particular use. The series
of extrusion heads, for applying adhesive to edge 42, as shown in
FIG. 5, is currently preferred because of its high reliability and
low cost.
Other methods of applying adhesive are known and may be used with
the system of the present invention. For example, eight extrusion
heads can be used instead of four to extrude beads of adhesive onto
the pocket material 31. An extrusion head in the shape of a bar can
be used, instead, where either beads of adhesive or a strip of
adhesive is applied along the length of the head. Extrusion heads
of both types are commercially available from Slautterback Corp. of
Monterey, Calif. In addition, a combination of several types of
extrusion heads may be used.
The adhesive may also be printed onto the pocket material 31. There
are at least two types of printing which can be utilized: 1)
flexigraphic and 2) gravure. In both cases, adhesive is applied via
a printing roller which is rolled onto the pocket material 31.
Extrusion heads are preferred instead of printing because they are
less expensive and take up less space in the system. In addition,
an extrusion head which extrudes beads is preferred to other types
of extruding heads because bead extruding heads are less expensive
and more reliable. It is anticipated that a combination of printing
and extruding can also be utilized. For instance, the adhesive
could be applied to the edge 44 of the pocket web 31 by extruding a
continuous bead while the angled edges of adhesive 42 can be
printed on, or vice versa.
Different types of adhesive may be used to apply the pocket
material 31 to the folder material 11. Three types of adhesive
include resin-based, hot melt and animal-based adhesive. A hot melt
bead extrusion adhesive which is polymer-based is preferred and is
commercially available from H. B. Fuller Co. of St. Paul, Minn.
(Model No. 2055). Advantageously, the hot melt polymer adhesive
starts to cool and cure immediately after extrusion. When the hot
melt polymer is extruded in bead form, it contacts the cool web
material and develops a skin around the outer edge of the bead as
it starts to cool. With this type of adhesive, when the adhesive on
the pocket material 31 passes between the pressure roller 62 and
the S-wrap roller 55, the adhesive in the center of the bead, which
has not yet cured, is squeezed past the skin which has formed and
is pressed outward to cover a larger surface area than the original
bead. Advantageously, the polymer adhesive immediately begins to
cure when it hits the cool pocket material 31. Therefore, the
contact of the pocket material 31, adhesive, and folder material 11
between the pressure roller 62 and the S-Wrap roller 55 causes the
adhesive to fix the pocket material 31 to the folder material 11
after the materials have been pressed together.
With hot melt adhesives, the temperature of the adhesive is
important for either printing the adhesive or extruding it. If the
adhesive is too hot, it will string. If the adhesive is too cold,
it will not flow well. Therefore, based on the type of hot melt
adhesive selected, it is necessary to use the adhesive at a proper
temperature.
Resin-based adhesives are of the type which include an emulsion in
water. An example of this type of adhesive is Elmer's Glue. With
resin-based adhesives, the water in the adhesive must be dried out
before the adhesive cures, unlike the hot melt polymer adhesive
which does not have to be dried. In order to dry the adhesive, more
pressure rollers are used against opposing rollers to compress the
adhesive between the pocket material 31 and the folder material 11.
When the materials are pressed through a series of rollers, the
water in the adhesive is absorbed into the paper or flexible
material. This helps the adhesive to dry more quickly. Resin-based
adhesives may be either printed or extruded. As is evident if a
resin-based adhesive is utilized, more pressure rollers 62 in
conjunction with opposing rollers will be needed, thereby
increasing the cost of equipment and the amount of space which the
rollers take up within the system.
Referring again to FIG. 4, the pressure roller 62 exerts force onto
the S-Wrap roller 55 in order to press the pocket material 31 and
adhesive onto the folder material 11. The pressure roller 62 is
preferably forced downward upon the opposing roller by a spring,
such as a coil spring or air spring, or similar means. The pressure
roller is preferably composed of a resilient or rubber-like
material. The preferred material for the pressure roller is
polyurethane. The pressure roller 62 may be pressed against a
series of stops (not shown) by the force of a spring so that it
exerts pressure on the opposing roller 55. It is desirable to
eliminate any bounce between the pressure roller 62 and the
opposing roller 55 in order to have continuous contact between the
two rollers. Continuous contact helps to effectively adhere the
pocket material 31 to the folder material 11. The resilient
material and spring of the pressure roller 62 help to reduce this
possibility.
Referring again to FIG. 4, the S-Wrap rollers 54, 55 are a commonly
used method for feeding or driving flexible materials, such as
paper, through a system. It is also known to feed flexible
materials with a single driven roller. The S-Wrap rollers 54, 55,
however, are preferred because they maximize the contact of the
material with the rollers, thereby reducing gapping and sagging and
keeping the material engaged with the rollers. Since the means of
driving the materials through the system is friction, it is
desirable to maximize the contact area of the material with the
drive mechanisms, which is accomplished more readily with the
S-wrap rollers. Both S-wrap rollers 54, 55 are driven and are
preferably directly connected to each other by gearing, belting, or
the like, so that they rotate at the same speed.
Referring again to the system shown in FIG. 4, it is desirable to
utilize a timing mechanism to automatically perform the cutting and
adhesive extrusion. Timing is important to the effective operation
of the system since the cutting edge 74 must cut each angled edge
42 of adhesive substantially down the central axis of the edge in
order to create joined edges on each side of the cut. In addition,
the adhesive must be dispensed at equal intervals in order to
produce a consistently sized product. For a hanging file folder, a
width of 11 3/4" is used to produce a letter size folder for each
length of folder material 11. A legal size folder is produced from
a width of 14 3/4". Therefore a means for timing is preferably
provided.
In the preferred embodiment, an electronic mechanism and a rotary
mechanism are utilized for timing purposes, although it will be
evident to one skilled in the art that an entirely electronic
system or an entirely rotary system may be used. In the preferred
embodiment, as depicted in the flow-chart of FIG. 6, the drive
shaft of the S-Wrap rollers 54, 55 is turned by an energy source at
a constant speed. The S-wrap rollers 54, 55, in turn, drive the
folder material 11 through the system. The drive shaft is,
preferably, connected to the cutting assembly 72 by a series of
gears and pulleys. It is preferable to configure the gears and
pulleys so that each rotation of the drive shaft results in a
cutting movement.
In order to cut the combined material 70 into the desired width, it
is preferable that one rotation of the drive shaft results in the
advancement of a proper amount of folder material. This may be
accomplished by adjusting the diameter of the drive rollers or the
diameter of the drive shaft. It is also possible to accomplish this
result by adjusting the gearing or by similar means. The gearing
and pulleys which connect the drive shaft to the cutting edge serve
to transfer power from the drive shaft to move the cutting edge up
and down to perform the cutting.
It should be noted that a number of different types of cutting
edges may be used. For instance, a rotary cutter, may be used as
well as a guillotine, the type previously discussed, or the like.
Each type of cutter may be connected to the drive shaft by a series
of gears or pulleys in order to properly time the cut.
Timing of the system may also be accomplished by electronic means.
In the preferred embodiment, shown in FIG. 6, the adhesive
extrusion is governed by electronic means. It is preferable to use
a signal which coincides with the rotation of the drive shaft. This
may be accomplished by the use of a proximity switch located in the
vicinity of the drive shaft.
A metal flag may be mounted on the drive shaft so that when the
flag rotates into proximity with the proximity switch, the switch
turns on. When the metal flag rotates away from the switch, the
switch turns off, or vice versa. The proximity switch then sends a
reset signal to a programmable limit controller for signaling the
extrusion heads to extrude adhesive. An encoder can also be
connected to the drive shaft to send a regular series of countable
pulses to the programmable limit controller as the drive shaft
rotates. The proximity switch, controller, and encoder of the type
contemplated by the preferred embodiment are available from
Slautterback Corp. of Monterey, Calif.
It should be noted that, in the preferred embodiment, the signal
will only travel to the extrusion heads 58 which produce the angled
edge of adhesive 42 since the other extrusion head 56 creates a
continuous bead of adhesive 36 and is not turned on and off during
the cycle. It should also be noted that physical rotary devices
such as cams, or the like, may be used in place of electronic
signalling. The cam actuates a relay or an air switch, or the like,
which actuates the extrusion head to extrude adhesive. A cam,
however, is less desirable than the proximity switch because if an
adhesive edge of a different width is desired, the cam has to be
replaced. Also, the cam can bounce and/or wear. It should also be
noted that more sophisticated controllers such as programmable
logic controllers or computers may be used in place of the
programmable limit controller. In addition, gears and pulleys may
be particularly useful if printing is used instead of
extrusion.
The programmable limit controller starts the count at zero and
counts upward until it is signalled by the proximity switch to
reset. In the preferred embodiment, the reset signal comes from the
proximity switch. Other forms of signalling to reset the counter in
the programmable limit controller can be used such as an "electric
eye" optical beam, and the like.
The encoder provides continuous countable pulses. During each
counting cycle, the programmable limit controller is programmed to
signal the extrusion heads 58 to emit beads of adhesive 42 at
discrete time periods, or counts. In operation, for example, the
encoder may provide 1000 pulses per revolution of the draft shaft.
The counter may be reset by the proximity switch once per
revolution of the drive shaft. The programmable limit controller
can be programmed to signal the extrusion heads 58 to extrude
adhesive 42, for example, between count 300 and 375. If the cutting
mechanism is governed electronically, the encoder can also be
programmed to signal the cutter 74 to cut at, for example, count
700. In this way, the operations of the cutter 74 and extrusion
heads 58 may be staggered in order to create pockets 30 on the file
folders 40. Therefore, the system can be timed to prepare any size
folder/pocket by modifying the programming of the programmable
limit controller and the amount of material fed through the system
during each cycle. Where either the extrusion heads or the cutting
assembly 72 are timed via rotary means, the gearing will be
configured so that the cutting and extruding are coordinated with
each other to provide a properly sized file folder.
There are other known ways to time the operation of the system. For
example, a cam can be mounted on the drive shaft to reset the
counter in the programmable limit controller instead of the
proximity switch. Also, the cam can bounce and/or wear.
Referring now to FIG. 7, the method of manufacturing a file folder
having a pocket includes several steps. First, an edge of adhesive
36 is deposited along a bottom edge 44 of the pocket material 31.
The edge of adhesive deposited along the bottom edge 44 is
preferably continuously deposited. The pocket material is also
referred to as the first web. Concurrently, a plurality of lines,
bars, or beads of adhesive are extruded onto the pocket web 31
along another edge 42.
The edges of adhesive 42 are positioned at an angle relative to the
continuous line 36 and are preferably perpendicular to the
continuous line of adhesive 36. The bar of adhesive is preferably
made up of a series of extruded beads. The combination of the
continuous line and the angled edges 42 form continuous attached
patterns of adhesive in the shape of a "U". The angled edges of
adhesive 42 preferably have a width which is sufficient in size so
that when the angled edges are cut in half, two joined edges 46 are
created to form two separate pocket edges.
After the adhesive is applied to the pocket material 31, the pocket
material 31 and the folder material 11 pass between a
pressure-exerting roller 62 and a driven roller 55. The folder
material 11 is also referred to herein as the second web. The
driven roller 55 drives the materials through the system. The
pressure roller 62 exerts force on the materials so that the
adhesive is pressed between the two webs, the adhesive thereby
spreading out slightly.
After the pocket material 31 has been joined to the folder material
11, the combined material 70 passes under a cutting edge 74. The
cutting edge 74 moves downward to cut the combined material 70 into
separate pieces, each piece identifying a separate file folder. The
cutting edge 74 cuts the combined material 70 along an axis defined
substantially through the center of the angled edges of adhesive
42. The cutter 74 cuts through the angled edges 42 so that the
adhesive is disposed on both sides of the cutting edge 74 to form
two joined edges 46 on either side of the cut.
It should also be noted that a reciprocating process of cutting the
combined material 70 may be used in place of a continuous cutting
process. With the reciprocating process, the combined material 70
is temporarily halted in order to perform operations on the
material, such as adding hanging file folder features. When the
material is stopped, the cutting may occur. The material may be
stopped by placing a bar over the moving material to hold it in
place temporarily or by other known means.
Since the cutting edge 74 cuts through an axis of each angled edge
of adhesive 42, a U-shaped adhesive layer remains on each
individual file folder. The U-shaped adhesive connects the pocket
web 31 to the folder web 11 and results in the formation of a
pocket on the folder. Advantageously, the side edges of the pocket
38 are in sheared alignment with the side edges of the folder,
creating a clean edge on the file folder where the folder and
pocket meet. Since a clean edge is created on each file folder, it
is never necessary to align the pockets on the folder after the
folder has been created or to trim the pockets separately to fit
onto the file folders.
The process also, preferably, is timed so that the angled edges of
adhesive 42 are applied at a proper location and so that the
cutting edge severs the combined material 70 through an axis of
each angled edge of adhesive 42 to create a pocket 30. The axis is
preferably located substantially centrally down the length of the
adhesive 42. Again, this timing may be accomplished by either
rotary or electronic means. The above described process is
desirable over other processes in that it is reliable and simple.
Rather than having to pre-cut pockets and time their placement onto
the folder material, or hand place them, the process places the
pocket by conveying sheets of material and severing them after the
materials have been combined. The process is not handicapped by
speed limitations, the only limitations being the strength of the
materials being utilized.
As shown in FIG. 8, the above-described method for manufacturing a
file folder having a pocket may be expanded upon in order to create
a hanging file folder. In this process, it is preferable to select
different colors for the pocket material 31 and the folder material
11 in order to provide visual differentiation between the two
materials. It is, likewise, preferable to select different colors
for the two webs when creating a file folder.
After the adhesive has been deposited on two edges of the first web
and the first web has been pressed against a second web to join the
webs along the edges of adhesive, the webs are cut through one of
the edges to form a sheet with a pocket. The sheet may then be
folded along a medial line 16 to form a bottom edge 16 with first
12 and second 14 side wall portions which are joined at the bottom
edge 16. The first 12 and second 14 side wall portions have upper
terminal edges 17. Slots 18 may be provided along the upper
terminal edges for placement of labeling tabs. The upper terminal
edges 17 may then be folded upon themselves in order to form a
channel and a rod member 20 may be placed in the channel. The rod
member is used to hold the hanging file folder within a storage
space, such as a filing cabinet.
It should be understood that variations and modifications within
the spirit and scope of the invention, beyond those discussed
herein, may occur to those skilled in the art to which the
invention pertains. Accordingly, all expedient modifications
readily attainable by one versed in the art from the disclosure set
forth herein are to be included as further embodiments of the
present invention. The scope of the present invention accordingly
is to be defined as set forth in the appended claims.
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